Nonwoven Fabric Thermobonding Pattern for Liquid Permeability
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Solution Overview
Problem
Existing nonwoven fabrics face challenges with reduced flexibility and permeability due to thermobonding at fiber intersections, leading to decreased strength and increased wetback when exposed to liquids.
Innovation Solution
A nonwoven fabric structure featuring alternately arranged thermobonded and non-thermobonded regions, where thermobonding is performed at fiber intersections without causing compression flattening, with non-thermobonded regions existing in a dispersed or linear form, and thermobonded regions having a greater thickness, allowing for improved fiber movement and liquid permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermobonding is performed at intersections of fibers throughout the entire nonwoven fabric, then the nonwoven fabric gains structural stability and strength, but flexibility and permeability of highly viscous liquids are reduced
Solution Approach 1:
The patent applies local quality by creating distinct thermobonded regions and non-thermobonded regions within the same nonwoven fabric. Thermobonding is performed only in specific regions to provide strength where needed, while leaving other regions non-thermobonded to maintain flexibility and liquid permeability. This spatial differentiation of bonding characteristics resolves the contradiction between overall strength and local flexibility.
Solution Approach 2:
The nonwoven fabric is segmented into multiple functional regions: thermobonded regions for structural support and non-thermobonded regions for flexibility and liquid flow. This segmentation allows different parts of the fabric to perform different functions simultaneously, resolving the contradiction between strength and flexibility by distributing bonding characteristics across different segments.
2Stability of the object's composition
If thermobonding is performed at intersections of fibers throughout the entire nonwoven fabric, then structural stability is improved, but permeability of highly viscous liquids is reduced
Solution Approach 1:
The patent creates local quality differentiation by confining thermobonding to specific regions rather than applying it uniformly. This allows thermobonded regions to provide structural stability while non-thermobonded regions maintain open fiber intersections that facilitate liquid permeability, thus resolving the contradiction between structural stability and liquid flow capability.
3Ease of operation
If thermally non-connected regions are continuously arranged on the surface, then flexibility is improved, but strength of the nonwoven fabric is reduced
Solution Approach 1:
The patent segments the nonwoven fabric into alternating thermobonded and non-thermobonded regions arranged in a specific pattern. This segmentation ensures that non-thermobonded regions providing flexibility are interspersed with thermobonded regions providing strength, rather than having continuous non-thermobonded areas. The alternating pattern balances both properties.
Solution Approach 2:
The patent transitions from considering only surface arrangement to incorporating thickness dimension by making thermobonded regions thicker than non-thermobonded regions. This dimensional differentiation allows the thermobonded regions to provide structural support through their greater thickness while non-thermobonded regions maintain flexibility through their thinner profile and lack of bonding.
4Ease of operation
If thermally connected regions are scattered on thermally non-connected regions, then flexibility is maintained, but surface roughness increases and drape is reduced
Solution Approach 1:
The patent introduces asymmetry in the vertical dimension by making thermobonded regions thicker than non-thermobonded regions. This asymmetric thickness distribution, combined with the alternating pattern, creates a more uniform surface profile compared to scattering thick thermobonded regions on a thin non-thermobonded background. The asymmetric design improves drape by reducing surface irregularities.
5Ease of manufacture
If non-thermobonded regions have the same thickness as thermobonded regions, then manufacturing simplicity is maintained, but absorption performance and bulkiness are reduced when wet
Solution Approach 1:
The patent applies local quality by differentiating the thickness of different regions: thermobonded regions are made thicker to maintain structural integrity and bulkiness, while non-thermobonded regions are made thinner to allow fiber flexing and liquid absorption. This localized thickness differentiation optimizes both absorption performance and manufacturing efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The fabric achieves high strength and flexibility while enhancing permeability and absorbency of highly viscous liquids, reducing wetback and maintaining bulkiness.
Implementation Method 1
thermobonding is performed by the thermo-fusible conjugate fibers in the thermally connected region (I)
Implementation Method 2
thermobonding is performed at intersections of the fibers without causing compression flattening in the fibers in the thermobonded regions
Data Source
Figure 1~2
Figure 3
AI summary
A nonwoven fabric that is excellent in permeability and absorbency of a highly viscous liquid, and can further reduce wetback of the liquid and has flexible drape, and a product obtained using the same. The nonwoven fabric is obtained using thermobondable fibers, in which non-thermobonded regions where no thermobonding is performed at intersections of the fibers, and thermobonded regions where thermobonding is performed at the intersections of the fibers alternately exist on a surface of the nonwoven fabric, and the non-thermobonded regions exist in a dispersed manner in a dot form, or continuously or intermittently exist in a linear form, and thermobonding is performed at the intersections thereof without causing compression flattening in the fibers in the thermobonded regions.